Precision built staircase

ABSTRACT

A precision built staircase that includes a plurality of stringers that include a structural stringer, a decorative stringer and a winder stringer that are cut by a high precision machine, a universal skirt board, a plurality of risers with a pair of ends and a plurality of universal squares. The staircase also includes a plurality of winder treads wherein the stringers, the skirt board, the risers and the treads form a plurality of stairs, a recessed tread end cap, one or more cover joints and corner joints to cover a plurality of cuts, a decorative panel disposed on the back of staircase after the stairs are formed and a packaging box that stores a plurality of unassembled staircase components and that forms a cabinet or a closet when empty.

This application claims priority to U.S. Provisional Application61/374,571 filed on Aug. 17, 2010, the entire disclosure of which isincorporated by reference.

TECHNICAL FIELD & BACKGROUND

The present invention relates to a staircase. More specifically, thepresent invention relates to a precision built staircase.

It is therefore an object of this invention to provide a precision builtstaircase that is relatively quicker and easier to assemble, has arelatively more (longer lasting) aesthetically pleasing appearance andutilizes relatively more precise pre-manufactured profiled structuralstringers and pre-profiled decorative stringers than current staircases.

It is another object of the invention to provide a precision builtstaircase with an added standard or universal skirt board and aplurality of accessories that can be assembled in a few minutes that arein compliance with various building codes and standards.

It is also an object of the invention to provide a precision builtstaircase with a plurality of components with a plurality of aestheticembodiments that can be manufactured on precision machinery such as aCNC router machine. (preferably face to face for a raw material economyfrom 26 to 38% for the first set of structural stringers and eliminatethe need to make and other set when come the time to install thedecorative final staircase (another 100%)

It is an object of the invention to provide a precision built staircasethat ensures consistent dimensional productivity and installation at theright position with a plurality of winder's treads and risers set byutilizing a starter winder tread plank and a pre-profiled nose angled toa plurality of winder's treads that are also relatively easy to fix,well-aligned at the front surfacing and angled at 90 degrees to thefront of the starter winder tread plank and are relatively quicklyinstallable into a starter winder tread plank slot for a relativelybetter final result.

It is another object of the invention to provide a precision builtstaircase that allows relatively easy and rapid assembling andattachment of the staircase components that includes a plurality ofpre-drilled apertures and a plurality of standard and Universal bracketsthat can be glued together without any excess overflow of glue to aplurality of treads, risers and stringers.

It is also another object of the invention to provide a plurality ofstandard and Universal skirt board that can be temporarily orpermanently used at a plurality of predetermined heights that areattached securely with one or more covers and one or more corner joints.

It is an object of the invention to provide a precision built staircasewith a plurality of components that could be easily sold and kept instock across all distributors, retailers, agents, installers, finishersand do-it-yourself suppliers on the market.

It is another object of the invention to provide a plurality ofprecision built staircase components that can be easily stocked in aweather regulated warehouse or store, that includes structuralstringers, decorative stringers, universal skirt boards and other staircomponents that will not warp, curve, crack or split by using kilndried, engineered composite materials and/or others.

It is another object of the invention to provide a precision builtstaircase in a kit form in a pre-assembled box that can be used as acabinet, a closet or an outside shell that is also available in apre-finished or a non-finished form.

It is another object of the invention to provide a precision builtstaircase that can utilize a plurality of different sizes, types,lengths, gages, with or without headed nails and screws.

It is another object of the invention to provide a precision builtstaircase that is made of composite, hard, softwood, aluminum, steel,concrete, marble, granite, rough or prefinished materials, or othersuitable engineered materials pre-assembled or non-pre-assembled.

It is another object of the invention to provide a precision builtstaircase that can utilize a wide variety of glue types.

It is another object of the invention to provide a precision builtstaircase and related components that can be manufactured in any desiredshape, size, and/or dimension.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will be described by way of exemplary embodiments,but not limitations, illustrated in the accompanying drawing in whichlike references denote similar elements, and in which:

FIG. 1 is a front side perspective view of a staircase having a firsttread with a recessed tread end cap, a new structural stringer, a newuniversal square, a new decorative stringer and a pre profiled skirtboard with the new universal square fit into the structural stringer, inaccordance with one embodiment of the present invention.

FIG. 2 is an exploded front side perspective view of a staircase with apre profiled skirt board and a decorative stringer, in accordance withone embodiment of the present invention.

FIG. 3 is a front side perspective view of a temporarily installedpreliminary staircase, in accordance with one embodiment of the presentinvention.

FIG. 4 is a side perspective view of a pair of skirt boards manufacturedfrom a panel, in accordance with one embodiment of the presentinvention. Face to face

FIG. 5 is a side perspective view of a pair of radius stringersmanufactured from a panel, in accordance with one embodiment of thepresent invention.

FIG. 6 is a side perspective view of a pair of square stringersmanufactured from a panel, in accordance with one embodiment of thepresent invention.

FIG. 7 is a side perspective view of a pair of angled outside radiusstringers manufactured from a panel, in accordance with one embodimentof the present invention.

FIG. 8 is a side perspective view of a pair of horizontal outside radiusstringers manufactured from a panel, in accordance with one embodimentof the present invention.

FIG. 9 is a side perspective view of a pair of vertical outside radiusstringers manufactured from a panel, in accordance with one embodimentof the present invention.

FIG. 10 is a side perspective view of a pair of winder inside radiusstringers manufactured from a panel, in accordance with one embodimentof the present invention.

FIG. 11 is a side perspective view of 4 universal squares manufacturedfrom a panel with a plurality of tapered apertures drilled at apredetermined angle to receive a plurality of screw treads and aplurality of risers pre-nailed or screwed to a plurality of structuralstringers, in accordance with one embodiment of the present invention.

FIG. 12 is a side perspective view of a universal square attached to astructural stringer, in accordance with one embodiment of the presentinvention.

FIG. 13 is a front side perspective view of a standard riser with aplurality of apertures and grooves for glue overflow, in accordance withone embodiment of the present invention.

FIG. 14 is front side perspective view of a dowel and spring and a toptread, in accordance with one embodiment of the present invention.

FIG. 15 is an overhead side perspective view of a tread with apositioned slot to receive a dowel of a riser, in accordance with oneembodiment of the present invention.

FIG. 16 is an bottom side perspective view of a tread with a positionedslot to receive a dowel of a riser, in accordance with one embodiment ofthe present invention.

FIG. 17 is an overhead side perspective view of a tread and riserassembly at a level of a spring-dowel with a positioned slot to receivea dowel of a riser and a groove at a rear of tread, in accordance withone embodiment of the present invention.

FIG. 18 is an overhead side perspective view of a pair of grooves at arear of a tread, in accordance with one embodiment of the presentinvention.

FIG. 19 is a top perspective view of a first winder's tread fit at astarter winder tread plank, in accordance with one embodiment of thepresent invention.

FIG. 20 is side perspective view of a winder starter plank with aplurality of align recessed noses of a first winder's tread, a secondwinder's tread and a third winder's tread with a decorative jacket, inaccordance with one embodiment of the present invention.

FIG. 21 is a side perspective view of a second winder's tread fit at awinder starter plank, in accordance with one embodiment of the presentinvention.

FIG. 22 is a side perspective view of a third winder's tread fit at awinder starter plank, in accordance with one embodiment of the presentinvention.

FIGS. 23 A-J are a plurality of side perspective views of a plurality ofshapes of a plurality of pre-profiled stringers, pre-profiled decorativestringers, standard and universal skirt boards, standard and universalsquares and bars, in accordance with one embodiment of the presentinvention.

FIG. 24 is a front side perspective view of a packing box, in accordancewith one embodiment of the present invention.

FIG. 25 is a rear perspective view of a precision built staircase, inaccordance with one embodiment of the present invention.

FIG. 26 is a side perspective view of a precision built staircase, inaccordance with one embodiment of the present invention.

FIG. 27 is an overhead side perspective view of a reversiblestringer-tread support, in accordance with one embodiment of the presentinvention.

FIG. 28A is a side perspective view of an attachment screw, inaccordance with one embodiment of the present invention.

FIG. 28B is a front perspective view of an attachment screw, inaccordance with one embodiment of the present invention.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

Various aspects of the illustrative embodiments will be described usingterms commonly employed by those skilled in the art to convey thesubstance of their work to others skilled in the art. However, it willbe apparent to those skilled in the art that the present invention maybe practiced with only some of the described aspects. For purposes ofexplanation, specific numbers, materials and configurations are setforth in order to provide a thorough understanding of the illustrativeembodiments. However, it will be apparent to one skilled in the art thatthe present invention may be practiced without the specific details. Inother instances, well-known features are omitted or simplified in ordernot to obscure the illustrative embodiments.

Various operations will be described as multiple discrete operations, inturn, in a manner that is most helpful in understanding the presentinvention. However, the order of description should not be construed asto imply that these operations are necessarily order dependent. Inparticular, these operations need not be performed in the order ofpresentation.

The phrase “in one embodiment” is used repeatedly. The phrase generallydoes not refer to the same embodiment, however, it may. The terms“comprising”, “having” and “including” are synonymous, unless thecontext dictates otherwise.

In accordance with these objects which will be discussed in detailbelow, the present invention provides a complete line of modified staircomponents and, when assembled together with a plurality of accessoriesand a stair kit reduce installation time, achieve a relatively higherpercentage savings of raw material, manufacturing time, and installationtime with a relatively high precision.

FIG. 1 is a front side perspective view of a staircase having a firsttread with a recessed tread end cap, a structural stringer, a universalsquare, a decorative stringer and a pre-profiled skirt board with theuniversal square fit into the structural stringer, in accordance withone embodiment of the present invention.

The invention relates to a staircase 500, more particularly, theinvention relates to modifications and ameliorations brought to aplurality of typical staircase components utilized that make thestaircases relatively easier to install and are typically moreeconomical to manufacture saving manufacturing time, raw material and 30to 70% of the installation time due to the relatively high precision ofpreferred machinery (e.g. CNC router) used to produce many of thestaircase components 500. When all of the components will be assembled,the final result will be a relatively better temporary or permanent fit.It will permit the re-use of the structural stringer 3 installed at thebeginning of construction permanently and only replace a rough tread 18and a riser 17 initially temporary installed by a plurality of chosendecorative treads 1-10 and risers 200, a decorative stringer 4, apre-profiled skirt board 5 and any other desired components,pre-finished or to be finished.

Staircases currently available on the market are mostly assembled on ajob site and to save installation time, few distributors offer thempre-assembled which can also be prefinished. When assembled on a jobsite, most of the time, stringers 3 are cut manually with a skill sawtypically 2″×2″×12″ which is where precision discrepancies occur. Whenthe staircases are assembled at a manufacturing site, they do notnecessary have the high precision machines (CNC router) to perfectly cutthe stringers 3, 4 and other high precision components cut. Typicallyit's very difficult to determine in advance the precision squaring andleveling the walls, floors and ceiling formed 95% of the time in a newbuilding or a remodeled job site, resulting that some percentage ofcomponents fabricated or adjusted on site must be reprocessed, resultingin a relatively costly operation.

Installation of staircase 500 is considered by professional buildingcontractors to be relatively complicated work. It is imperative tointroduce into a relatively large market, products that can be installedin less time and with more efficiency and precision. Structuralstringers 3 are a significant part of substantial saving inmanufacturing, raw material, installation time and an attractive finallong lasting aesthetic appearance. Regarding the stringers 3, 4 andpre-profiled skirt board 5; the manufacturing's precision and relativerapid execution offer distributors, retailers and others a reasonableprice and better compliance of building codes. Structural stringers, 3,decorative stringers 4, a pre-profiled skirt board 5 and a plurality ofwinder's treads 201,202,203 can be manufactured in a through panel, thatcan also be reversible, made of many materials such as engineered,laminated, plywood, composite, kiln dried or other suitable materials toreduce the components curving, warping, cracking, shrinking or expandingtoo much. All these elements are required to be avoided so that precisemanufacturing at the beginning of the manufacturing process may avoidthe need to reinstall new stringers 3, 4 when it's time to install thefinal permanent decorative staircase.

FIG. 4 is a side perspective view of a pair of skirt boards manufacturedfrom a panel attached face to face, in accordance with one embodiment ofthe present invention.

The height of risers 47A and tread's runs 46 staying precise allowsfurther ameliorations to these components for an easier and quickerinstallation.

FIG. 6 is a side perspective view of a pair of square stringersmanufactured from a panel, in accordance with one embodiment of thepresent invention.

The pair of skirt boards includes a plurality of stringer types501,601,701, 801, 901, 1001, risers 200 treads 1, 10, 18, dowels 205,springs 206, aperture 210, slot 208, profiles and grooves 701A, 801A.

FIGS. 23 A-J are a plurality of side perspective views of a plurality ofshapes of a plurality of pre-profiled stringers, universal skirt boards,universal squares and bars, in accordance with one embodiment of thepresent invention.

FIGS. 23 A-J illustrates contact between some of the components thatpermit a relatively better adjustment when assembled temporarily and/orpermanently together. The staircase 500 attempts to correct or hideimperfections in cutting and assembling and/or further variations ofadjacent construction components. The staircase 500 attempts to minimizethe time of installation, to maximize the quality of assembly and tominimize the touch-up areas. Risers 200 are attached to treads 112underneath through angled apertures 208 A at specific angles typicallywith round headed screws 209 that are self-drilled and tempered.Addition of a plurality of grooves to the top of riser groove 207 orbottom front 200A permits a better grip and possibility to add glue 19such as PL type glue, typically in permanent installation withoutregarding height of the standard risers desired and minimizing overflowsof glue onto unwanted portions of the risers.

Universal square 15 firmly maintains the desired position in regards totemporarily or permanently attached treads 1-10, risers 200 and stringer3. Two pieces of sticky and spongy material 15A are added on top ofuniversal square 15 to be attached to treads 1-10 underneath and atleast one piece of sticky and spongy material 15A such as cork, foam,rubber, or felt are added at the vertical front side of the universalsquare 15 to be attached at the rear risers 200B. The piece of stickyand spongy material 15A is typically square or round and isauto-adhesive which will act as a spacer being squeezed when screwedthrough the bracket aperture from the back to the tread 1-10 and riser200, resulting in a relative tighter fit to the stringer 3.

FIG. 19 is a top perspective view of a first winder's tread fit at astarter winder tread plank, in accordance with one embodiment of thepresent invention.

Cover joint 18 a, 18 b, 18 c and corner joints 2540 will timeefficiently cover a plurality of cuts 18B at joint eliminating touch-upareas.

FIG. 20 is a side perspective view of a starter winder tread plank 101 aplurality of align recessed noses of a first winder's tread, a secondwinder's tread and a third winder's tread with a decorative jacket, inaccordance with one embodiment of the present invention.

Starter winder tread plank 101 assures the installation of winder'streads 1,2,3 to firmly and accurately align each other in a plurality ofpredetermined single recessed slots 1A,2A,3A at a predetermined preciseriser height desired and to tightly attach winder's risers 1B,2B,3B atright angles to the adjacent wall 550, starter winder tread plank 101,winder's treads 1,2,3 together.

Starter winder tread plank 101 assures the installation of winder'streads 1,2,3 to firmly and accurately align each other in a plurality ofpredetermined double recessed slots 1A,2A,3A and to tightly attachwinder's risers 1B,2B,3B at right angles to the adjacent wall 550,starter winder tread plank 101, winder's treads 1,2,3 together.

FIG. 2 is an exploded front side perspective view of a staircase 500with a pre-profiled skirt board 5 and a decorative stringer 4, inaccordance with one embodiment of the present invention.

Pre-profiled skirt board 5 will be installed relatively quickly withoutany scratches on treads or risers such as pre-finished treads or risersusing a plastic tape 6, with a resistant pre-glued 7 at one side of theplastic tape 6. The pre-profiled skirt board 5 is laid down over plastictape 6 preinstalled at a wall side over treads 10 and risers 1 then theuniversal skirt board 2631 is slid-up to the front of risers 1 and ispushed to the wall 550. One or more nails 16 or screws 19 that securethe pre-profiled skirt board 5 to wall 550 are hid with an overlapangled molding 560. The plastic tape 6 can be removed by manuallytearing-off the plastic tape 6. The plastic tape 6 can similarly beutilized for pre-profiled skirt board of a winder's set.

FIG. 3 is a front side perspective view of a temporarily installedpreliminary staircase, in accordance with one embodiment of the presentinvention.

One or more tread's end cap 11, 12, 13 shown in FIG. 1 can be added atone or both sides of tread 10 and formed recess (not shown) at a depthof the typical length of overpass of the decorative stringer 4 (opendecorative stringer) at ±50% of thickness of tread and at 100% or lessof the width of treads 116. The end cap 11,12,13 can be dimensioned andshaped as desired and will typically be disposed on the rear of tread113 to hide imperfect fits, hide a vertical 902, a horizontal 802 and/oran angled outside radius 702 of stringers 4 or simply for a decorativelook. Angled square 575 of any suitable outside or inside shape canbring the same corrections resulting in a different aesthetic appearanceat a lower price.

Bottom rear tread radius when tread are nosed right and or left side (tobe discussed

Pre-profiled 5 and universal skirt board 2631 adds a desired aestheticfit and hide nails 16 and/or screws 19 used at top side of treads 10 andrisers 1,17,200 and/or space between the wall 550 and treads and risers,when there is, in straight 500 or winder's installation

FIG. 19.

FIG. 21 is a side perspective view of a second winder's tread fit at astarting plank, in accordance with one embodiment of the presentinvention.

Decorative starter plank jacket 100 can be added any time after treadsand risers are installed over the rough starter plank 99 and holder ofstarter plank. To build a straight staircase 500 on-site will save from4 to 6 hours of installation time in contrast to a traditional staircaseand to built on site a L-shaped staircase 500 with a set of 3 winder'streads and risers, the saving time will be up to 6 to 9 hours incontrast to a traditional staircase. This relatively large time savingswill be appreciated by professional building contractors anddo-it-yourself customers who wish to install their own staircase.

FIG. 22 is a side perspective view of a third winder's tread fit at astaring plank, in accordance with one embodiment of the presentinvention.

Decorative starter plank jacket 100 can be added any time after treadsand risers are installed over the rough starter plank 99 and holder ofstarter plank. To build a straight staircase 500 on-site will save from4 to 6 hours of installation time in contrast to a traditional staircaseand to built on site a L-shaped staircase 500 with a set of 3 winder'streads and risers, the saving time will be up to 6 to 9 hours incontrast to a traditional staircase. This relatively large time savingswill be appreciated by professional building contractors anddo-it-yourself customers who wish to install their own staircase.

FIG. 15 is an overhead side perspective view of a tread with apositioned slot to receive a dowel of a riser, in accordance with oneembodiment of the present invention.

Prior to installing a plurality of rough risers 17 of treads 18,structural stringers 3 are installed at a precise position initiallywith glue and are then nailed or screwed to wall 550.

FIG. 16 is an overhead side perspective view of a tread with apositioned slot to receive a dowel of a riser, in accordance with oneembodiment of the present invention.

Top 207 and bottom of risers are nailed or screwed to riser height 570of structural stringer at an identical level to the top tread's runs580, the top of below riser which has at least one aperture, a dowel 205or a spring-dowel 205,206 to match the slot 208 in the front of andunderneath tread 116 to be typically nailed or screwed in a desiredprecise position.

FIG. 17 and FIG. 18 are an overhead side perspective view of a tread andriser assembly at a level of a spring-dowel with at least one groove andor a radius at a rear of a tread with a positioned slot to receive adowel of a riser, in accordance with one embodiment of the presentinvention.

Top 207 and bottom of risers are nailed or screwed to riser height 570of stringer at an identical level to the top tread's runs 580, the topof below riser which has at least one aperture, a dowel 205 or aspring-dowel 205,206 to match the slot 208 in the front of andunderneath tread 116 to be typically nailed or screwed in a desiredprecise position. The rear of tread 113 includes a tread radius 118 anda tread groove 119

FIG. 17 is an overhead side perspective view of a tread and riserassembly at a level of a spring-dowel with a groove at a rear of a treadwith a positioned slot to receive a dowel of a riser, in accordance withone embodiment of the present invention.

When the rough and/or decorative stair components are ready to beinstalled, a reversible universal square 15 could be secured by gluing,nailing or screwing to the inside structural stringer 3 at the back ofstaircase 500. The universal square 15 underneath the rough tread 18 isset in place and pushed to the back of the riser 17 that is alreadysecured in place. It is significant to install at least two previouslydescribed auto adhesive resilient material pieces 15A to the top of theuniversal square 15 and at least one, if desired, to the middle verticalfront of the universal square 15 to be used. This process can berepeated at all triple stringer contacts 3 to the left or right if thereare more than 2 structural stringers.

FIG. 11 is a side perspective view of 4 universal squares 15manufactured from a panel with a plurality of reversed tapered aperturesdrilled at a predetermined angle to receive a plurality of screw treadsand a plurality of risers pre-nailed to a plurality of structuralstringers, in accordance with one embodiment of the present invention.

After termination of these operations, all rough treads 18 and risers 17can be torn-out and ready to receive the new pre-finished or to befinished desired risers 200 and treads 10 to structural stringers 3 andpre-profiled decorative stringers 4. These components can be tightenwith suitable appropriated screws from the back of staircase 500 throughthe reversed taper apertures 215 at the underneath and the back ofuniversal square 15 to the underneath of treads and to the back of theriser. Any nailing and or screwing to top of treads and risers that willbe eventually hidden, will be permitted and facilitate the securing oftreads and risers from the back of universal squares 15.

FIG. 13 is a front side perspective view of a standard riser with aplurality of apertures and grooves for glue overflow, in accordance withone embodiment of the present invention.

When an end-user desires a permanent and solid installation, glue istypically applied to the structural stringers 3 at the suggested groovedshape at tread's runs 580 and/or to the riser's heights 570, top ofrisers length 207 and/or bottom front riser's grooves 202B to the riserto be tighten to the rear of tread 113 or the rear of tread slot orgrooves 119 to be tighten to front bottom of standard riser 200B throughthe desired pre-drilled apertures 203B at the bottom of the riser withappropriated screws, introduced at the back of the standard riser rearbottom. The typical screws to be used for the staircases' installationare a plurality of rounded head screws 209 that are self-drilled formingangled apertures 208A and tempered of suitable appropriated lengths. (acomplete kit of screws needed for the installation of chosen staircasewill be available for sale) and other ways to save time and errors.

FIG. 10 is a side perspective view of a pair of winder inside radiusstringers manufactured from a panel, in accordance with one embodimentof the present invention.

Standard holder bar (not shown) will come at a plurality ofpredetermined lengths and typically has the same dimensions as the topof the longer side of the universal square 15 and will be secured at therear of the universal square 15 when more strength is needed to attachtreads to tread's runs of stringer (e.g. Winder's tread 1, 2, 3 towinder's stringers 1001).

FIG. 12 is a side perspective view of a universal square attached to astructural stringer, in accordance with one embodiment of the presentinvention.

Similar suitable techniques to form or drill angled apertures andtapered apertures will be applied as well including securely screwingtreads and risers to tread's runs of stringers 580 with a plurality ofpreviously described pieces of sticky and spongy material 15A placedbetween stringers 580.

Any corner joints 18 b, 2542, 2570, cover joints 18 c, 2540, 2560, 2585,or starter winder tread plank 101 will be used to hide jointed cuts(good or bad), nails 16 or screws, acting as a recess for pre-profiledand universal skirt board 5, pre-profiled decorative stringers 4, treads10 and risers 1-200. Some molding with angled overlap 560 will be hid aswell, over and at the side of these prefinished or non-prefinishedcomponents.

FIG. 5 is a side perspective view of a pair of inside radius stringersmanufactured from a panel, in accordance with one embodiment of thepresent invention.

Some pre-shaped inside square cover 13 with or without an inside 502 oran outside radius 702,802,902 can be added to bottom rear tread outsideof decorative stringer 4 and/or square angles 602 to match and covermanufactured inside 502 and the bottom shape of rear tread when treadare nosed at side(s).

FIG. 7 is a side perspective view of a pair of angled outside radiusstringers manufactured from a panel, in accordance with one embodimentof the present invention.

The pre-shaped inside square cover 13 also includes outside radius702,802,902 or square angles 602 at the rear and or bottom of lateraloverlapped tread's nose.

FIG. 8 is a side perspective view of a pair of horizontal outside radiusstringers manufactured from a panel, in accordance with one embodimentof the present invention.

The pre-shaped inside square cover 13 also includes outside radius702,802,902 or square angles 602 at the rear and or bottom of lateraloverlapped tread's nose.

FIG. 9 is a side perspective view of a pair of vertical outside radiusstringers manufactured from a panel, in accordance with one embodimentof the present invention.

The pre-shaped inside square cover 13 also includes outside radius702,802,902 or square angles 602 at the rear and or bottom of lateraloverlapped tread's nose.

The back of staircase 500 has to be finished and frequently theprofessional contractor installer or painter is required to returnseveral times to completely finalize the staircase construction, whichcan be relatively costly. One way to eliminate this is to supplystandard backing panels (not shown) to be adjusted to the back ofstaircases to be typically equally cut at the jobsite at each side, tobe properly fit, pre-finished and fabricated from any suitable materialavailable. The backing panel of staircase can be pre-finished ornon-prefinished, plain or with any suitable types of printed, pressureprinted, molded designs, grooved or with any suitable designs, texturalfinish or composition of products adaptable to the back of staircasesstringers 3 or 4. Many different types of molding (not shown), shaped ordesign, can be added to all joints and or walls, floors or ceilingsadjacent to staircases. If the stairs, backing panel and moldings arepre-finished, there is no need to have other professionals come back tofinalize the construction of the staircase, resulting in a substantialsavings of time and money with a relatively more convenient decorativefinal result. The decorative backing panel of the staircase can beinstalled with a plurality of nails or a plurality of screws with orwithout glue with preferably some backing cross-member installed betweenstringers when necessary and desired sound padding can be added betweenstandard backing panel and back of treads and risers. Any molding shouldbe installed in a floating orientation secured to the wall and shouldallow for shrinking and expansion variations of structure that do notaffect the final aesthetic appearance.

Stringers riser's radius 502 could be disposed on riser rear bottom 131typically to decorative angled standard risers to assemble with angleddecorative stringer's risers' predetermined height and if the height ofriser 200 is too wide, the predetermined height of the riser can be cutat a desired height minus radius 502 or at ±15 degrees from the frontbottom riser predetermined height. Typically all risers 200 that areinstalled permanently as standard of any length should be pre-cut ateach end at a 45 degrees angle or more and more typically at a 47degrees angle 590, where the fit with decorative stringer riser heightpre-angled cut will be typically suitable and if the riser angle is notnecessary can be cut square as needed without creating an inadequatefit.

FIG. 14 is front side perspective view of a dowel and spring and a toptread, in accordance with one embodiment of the present invention.

Some others modifications to risers 200 and treads 10 will attach themat the right position quickly, precisely and tight fit togethertemporarily and/or permanently (with or without glue) to underneathfront of tread 200 A. One of these is, at least one aperture 203A, 203Blocated at the approximate middle of the top riser length and plus orminus half-thickness of the riser to insert a dowel 205 or preferably aspring 206 plus an appropriated dowel 205 in wood or in other materialto the bloc riser at the desired position when dowel 205 is engage inlimited slot 208 length at the same distance underneath the tread nose.The dowel 205 is introduced in the slot 208 by the pressure action ofthe spring pushing the dowel 205. When both the dowel 205 and the slot208 are connected together, the standard riser 200 is ready to bescrewed securely underneath the tread 116 without slipping out of slot,through angled apertures 208A pre-drilled from back of riser 200 B totop of riser with suitable appropriated screws 209. Risers 200 has atleast one marker line 201A.

This eliminates steel squares or pre-drilled blocs onsite, usually usedby professional contractors. The preferred shapes at the top of theriser should be a W-shaped section FIG. 23 F and or triple V-shapedsection FIG. 23 J (e.g. a double big V-shaped section and small V-shapedsection disposed in middle of riser). This triple V-shape will allowglue to be disposed with a gun at the middle V-shaped section tooverflow in double V-shaped section of each side when the treads andrisers will be tighten together. At the bottom front 200A of standardriser 200 at least one groove and typically 3 grooves are provided topermit adhesion and accommodate overflow of glue when rear of bottomtread and bottom front riser are secured together through at least oneaperture of a plurality of apertures 203B that are pre-drilled and areaccommodated with one or more suitable appropriated screws 209.

Typically when installers assemble a temporary staircase on a job siteare replaced by a decorative staircase, rough treads 18 and risers 200are nailed to a structural stringer 3, however this is not possible whendecorative threads and risers are installed. The staircase 500 remediesthis and allows a pre-profiled universal skirt board to be installed atthe wall over the nails and/or screws and potential wrong cuts and thenbe hidden by the thickness of the universal skirt board.

FIG. 24 is a front side perspective view of a packing box, in accordancewith one embodiment of the present invention.

Packing box 2400 is provided to transport any staircase components thatneed to be protected when carried to the job site. Some components arerelatively long such as stringers 3, 4 and the universal skirt board2631 and are also relatively fragile to carry. More specifically whenprefinished, the packaging box 2400 should be solid and very protectiveand typically is relatively very costly. The packing box 2400 can alsohave a second use as a cabinet and/or closet with or without a door or acover 2430 that can also be split into two or more sections 2410 and2420 that can also be usable as furniture (e.g. a cabinet for tools andaccessories or a shoes cabinet open shell) or any other desired suitableutilities or applications, pre-finished or non-pre-finished. The packingbox 2400 can potentially save money, prevent environmental waste, aswell as protect staircase components to be delivered and serve as astrong marketing tool for a manufacturer, or any intervenient indistribution and sale of staircases and or other domains. The dualpurpose packing box 2400 can be adapted to any type of suitable productsto be carried needing suitable appropriated protection. The packing box2400 can be made of any suitable type of material, at any suitabledesired dimensions, engineered design, or other needed specification.Different kits of shells, doors and accessories associated with thepacking box 2400 will be available on request and can be customized withspecified specifications as well.

FIG. 25 is a rear perspective view of a back of the staircase, inaccordance with one embodiment of the present invention.

The back of the staircase 500 is attached to a first wall 2510, a secondwall 2520 and a third wall 2530. The back of the staircase 500 isattached between the first wall 2510 and the second wall 2520 and behinda third wall 2530. A skirt board starter joint 2540 attaches the back ofthe staircase 500 with the third wall 2530 typically at each corner ofthe back of the staircase 500. There is also a corresponding cap 2542disposed on each of the skirt board starter joints 2540 to protect theskirt board starter joints 2540. A winder starter plank 2550 attachesthe back of the staircase 500 to the first wall 2510. A cap 2552 is alsodisposed on the winder starter plank 2550 to protect the winder starterplank 2550. A middle skirt board joint 2560 attaches the back of thestaircase 500 to the second wall 2520. A cap 2562 is disposed on themiddle skirt board joint 2560 to protect the middle skirt board joint2560. An outside skirt board corner joint 2570 also attaches the back ofthe staircase 500 to the second wall 2520. A cap 2580 is disposed on theoutside skirt board corner joint 2570 to protect the outside skirt boardcorner joint 2570. A tread rim extender tread 2590 additionally attachesthe first wall 2510 to the back of the staircase 500. A tread rim 2595is disposed underneath the tread rim extender tread 2590 to furtherattach the back of the staircase 500 to the first wall 2510. Areversible molding 2575 also attaches the back of the staircase 500 tothe first wall 2510. A skirt board ender joint 2585 is disposedunderneath the reversible molding 2575 to further attach the back of thestaircase 500 to the first wall 2510. A cap 2587 is disposed on theskirt board ender joint 2585 to protect the skirt board ender joint2585.

FIG. 26 is a side perspective view of a precision built staircase 500,in accordance with one embodiment of the present invention.

The staircase 500 includes the reversible molding 2575 which is disposedon top of the staircase 500. There is also a cap 2610 on the top of thestaircase 500. The skirt board inside corner joint 2540 is underneaththe cap 2610. A tread rim bloc 2620 is disposed underneath the skirtboard start joint 2540. A tread rim extender 2630 is vertically andhorizontally attached to each vertical portion 2640 of each step 2642the staircase 500. The tread rim extender 2630 is attached to thevertical portion 2640 with a plurality of screws 2644. The tread rim2595 is then provided on the distal end 2650 of the horizontal portion2652 of each step 2642. The universal square 15 secures the verticalportion 2640 and the horizontal portion 2652 together. The overlapangled molding 560 has a pair of ends 562 with a flange 2660 provided onthe ends 562 of the overlap angled molding 560. The skirt board enderjoint 2585 and cap 2587 are provided at the bottom of the staircase 500.

FIG. 27 is an overhead side perspective view of a reversiblestringer-tread support 2700, in accordance with one embodiment of thepresent invention.

The structural stringer 3 has a plurality of grooves 2710 disposed ontop of the structural stringer 3. The grooves 2710 are typically convex2712 but can be any suitable shape. The grooves 2710 permit glue tooverflow and spill on either side of the grooves 2710 and permit abetter and larger grid surface, while also providing a better hold andattachment at the right level. There are one or more tape apertures 2720provided as well.

FIG. 28A is a side perspective view of an attachment screw 209, inaccordance with one embodiment of the present invention.

The attachment screw 209 includes a threaded portion 2810, a screw head2820 and a non-threaded portion 2830. The threaded portion 2810 isdisposed on a rear half 2802 with a distal end 2803 of the attachmentscrew 209. The round head 2820 is disposed on a proximal end 2804 of theattachment screw 209. The round head 2820 can be a Phillips head shaped2822 or any other suitable shaped screw head. The non-threaded portion2830 is disposed on a front half 2806 of the attachment screw 209 andaccommodates a thickness of any tread. There is also a self-drill end2840 disposed on the end of the distal end 2803. Right now on the marketthere is not a screw for this application that is more then gage number9. Gage number 10 or higher may be used in the application.

FIG. 28B is a front perspective view of an attachment screw 209, inaccordance with one embodiment of the present invention. The threadedportion 2810, the screw head 2820 and the non-threaded portion 2830 andtheir components of the attachment screw 209 are the same as illustratedand described in FIG. 28A. The screw head 2820 can be a Phillips headshaped 2822 or any other suitable shaped screw head as previouslydescribed in FIG. 28A.

Installation of the staircase and its components can be done from thetop of the staircase to the bottom of the staircase, eliminating theneed for an installer to walk on the tread during the installation,which is typically done during the installation. This also allows theinstaller to work alone without a helper during the installationutilizing a top to bottom installation.

The precision of the structural stringer and the prefabricatedcomponents assembled together permit the installation of a prefabricatedskirt board after the structural stringer, tread and riser areinstalled, something that is typically impossible to do with a regularinstallation with material currently on the market.

Most engineered skirt boards are typically installed in two or threeparts because single engineered skirt boards of a suitable length aretypically not available and are very difficult to carry and timeconsuming to manufacture especially with a fit-at-joint assembly. Theseengineered skirt boards are also less aesthetically attractive thanother relatively shorter skirt boards for end-user customers.

In FIG. 26 the universal skirt board will accommodate and accept arelatively wide variation of riser heights up to +/−⅞ths of the heightof the tread rim while preserving an aesthetically pleasing installedskirt board.

The packing box will permit the delivery of relatively longer componentssuch as full length skirt boards and full length molding without anxietyregarding the components being broken or damaged while beingtransported.

There is also a tread groove disposed at the rear of the tread toaccommodate any glue spillage and overflow and therefore relatively moreglue for a potentially stronger attachment. A plurality of multiplegrooves accommodate any glue spillage or overflow that are typicallyinstalled at the middle rear portion of the tread that are firmlysecured to the riser and tread together to minimize the possibility ofglue spillage and overflow over the tread top. The one or more groovesat the top of the riser also have the same function of catching gluespillage and overflow.

Any of the one or more grooves provide a strong, permanent and tightattachment of any adjacent components when the components are made ofwholly or partly engineered products, such as OSB, particleboard,fiberboard, plywood, LVL, LSL, softwood and other materials that caneasily possibly break, split or allow for a screw or nail to be easilytorn-off or removed.

The standard stringer tread support can also be reversible. A pluralityof grooves permit glue to overflow and spill on either side of thegrooves and permit a better and larger grid surface while also providinga better hold and attachment.

Typically the grooves are disposed around the sides of the stringer thatare cut with a shot leveler to lock down, align and set the reversiblestandard stringer tread support relatively quickly at a desired heightand level. Similar to all of the components of the staircase, thegrooves disposed around the stringer can be relatively quickly andeasily installed.

While the present invention has been related in terms of the foregoingembodiments, those skilled in the art will recognize that the inventionis not limited to the embodiments described. The present invention canbe practiced with modification and alteration within the spirit andscope of the appended claims. Thus, the description is to be regarded asillustrative instead of restrictive on the present invention.

1. A precision built staircase, comprising: a plurality of structural stringers; at least one riser with one or more grooves disposed on said risers to accommodate any glue overflow or spillage from any glue utilized to secure said risers; and at least one tread wherein said stringers, said risers and said treads form said staircase.
 2. The staircase according to claim 1, wherein said structural stringers are provided with at least one groove.
 3. The staircase according to claim 1, wherein said stringers are a selected one of a decorative stringer and a winder stringer.
 4. The staircase according to claim 3, wherein said stringers are cut by a high precision machine.
 5. The staircase according to claim 1, wherein said riser has at least one angled aperture, at least one pre-drilled aperture, at least one front riser groove and top of riser groove.
 6. The staircases according to claim 1, wherein said treads are a winder tread.
 7. The staircase according to claim 1 or 6, wherein said winder tread is a starter winder tread plank.
 8. The staircase according to claim 7, wherein said treads includes a tread radius and a tread groove.
 9. The staircase according to claim 1, wherein said treads include a recessed tread end cap.
 10. The staircase according to claim 1, wherein said winder treads are made of material selected from the group consisting of engineered material, laminated material, plywood material, composite material or kiln dried material.
 11. The staircase according to claim 1, wherein said staircase includes at least one universal skirt board, a plurality of universal squares with a horizontal top and one or more cover joints and corner joints to cover a plurality of cuts.
 12. The staircase according to claim 11, wherein said universal squares with said horizontal top are a reversible universal stringer support.
 13. The staircase according to claim 12, wherein one said groove connects said winder treads and one said groove connects one of said universal squares.
 14. The staircase according to claim 11, wherein said horizontal top accommodates a plurality of disposed auto-adhesive spacer pieces.
 15. The staircase according to claim 14, wherein said spacer pieces are made of material selected from the group consisting of cork, foam, rubber or felt.
 16. A precision built staircase, comprising: a plurality of stringers that include a structural stringer, a decorative stringer and a winder stringer that are cut by a high precision machine; a pair of universal skirt boards attached face to face; a plurality of risers with a pair of ends with one or more grooves disposed on said risers to accommodate any glue overflow or spillage from any glue utilized to secure said risers; a plurality of universal squares with a horizontal top; a plurality of winder treads wherein said stringers, said skirt board, said risers and said treads form a plurality of stairs; a recessed tread end cap; one or more cover joints and corner joints to cover a plurality of cuts; a decorative panel disposed on said back of staircase after said stairs are formed; a reversible universal stringer support; and a tread rim extender.
 17. The staircase according to claim 16, wherein said high precision machine is a CNC router.
 18. The staircase according to claim 16, wherein said horizontal top accommodates a plurality of disposed auto-adhesive spacer pieces.
 19. The staircase according to claim 18, wherein said spacer pieces are made of material selected from the group consisting of cork, foam, rubber or felt.
 20. The staircase according to claim 19, wherein said spacer pieces are square-shaped, vertical-shaped, square-shaped or round-shaped and are installed at any angle.
 21. The staircase according to claim 16, wherein said risers are installed and precut at each said end at an approximate 45 degree angle or more.
 22. The staircase according to claim 16, wherein said winder treads are made of material selected from the group consisting of engineered material, laminated material, plywood material, composite material or kiln dried material.
 23. The staircase according to claim 16, wherein one said groove connects said winder tread and one of said risers and one said groove connects one of said universal squares.
 24. A precision built staircase, comprising: a plurality of stringers that include a structural stringer, a decorative stringer and a winder stringer that are cut by a CNC router; a pair of universal skirt boards attached face to face; a plurality of risers with a pair of ends with one or more grooves disposed on said risers to accommodate any glue overflow or spillage from any glue utilized to secure said risers; a plurality of universal squares with a horizontal top; a plurality of winder treads wherein said stringers, said skirt board, said risers and said treads form a plurality of stairs, wherein one said groove connects said winder tread and one of said risers and one said groove connects one of said universal squares; a recessed tread end cap; one or more cover joints and corner joints to cover a plurality of skirt board cuts; a decorative panel disposed on said back of staircase after said stairs are formed; a packaging box that stores a plurality of unassembled staircase components and that forms a cabinet or a closet when empty; a reversible universal stringer support; a tread rim extender; a tread rim bloc; a universal reversible support, a winder starter winder tread plank, a tread rim, a tread rim extender tread, an outside skirt board corner joint, a skirt board starter joint, a skirt board ender joint, a middle skirt board joint, a reversible stringer-tread support and a plurality of corresponding caps to accommodate installing said staircase with a plurality of attachment screws that includes a threaded portion with a distal end with a self-drill end and a non-threaded portion to accommodate a thickness of said tread.
 25. The staircase according to claim 24, wherein said horizontal top accommodates a plurality of disposed auto-adhesive spacer pieces.
 26. The staircase according to claim 25, wherein said spacer pieces are made of material selected from the group consisting of cork, foam, rubber or felt.
 27. The staircase according to claim 25, wherein said spacer pieces are square-shaped, vertical-shaped, square-shaped or round-shaped and are installed at any angle.
 28. The staircase according to claim 24, wherein said risers are installed and precut at each said end at an approximate 45 degree angle or more.
 29. The staircase according to claim 24, wherein said winder treads are made of material selected from the group consisting of engineered material, laminated material, plywood material, composite material or kiln dried material. 